Transmission Autopsy (long)
02-06-2005, 05:10 PM
#46
And since I'm having fun with my rebuild too, if you have a external oil cooler, beware of the gasket that is in the pump. Most of your gasket sets do not include this little gem. The part number is 016115189. I am having a hard time finding this stupid part that only cost $1!
02-07-2005, 07:00 PM
#48
Drifting
Thread Starter
Good question Bob. I know the cryo brake rotor people claim wear resistance benefits; I'm not sure about fatigue life and I'm pretty sure the R&P failures are fatigue related (I'm sure mine was). I did try and contact Powerhause high perf gears but never got a response from them. It could be that the R&P design is limited by the design of the gear teeth (stresses too high) and improved heat treating may not be able to overcome that.
02-08-2005, 10:05 PM
#50
Drifting
Thread Starter
Can you not make one? You can buy similar gasket material and try to trace around the part and cut with scissors. Brush up on those first grade skills...
02-09-2005, 12:35 AM
#51
Three Wheelin'
Mike,
Any chance you want to give me some advice on my rebuild?
This post has encouraged me to attempt to rebuild the old unit out of my '88. Thanks very much for the excellent documentation.
-Jon
Any chance you want to give me some advice on my rebuild?
This post has encouraged me to attempt to rebuild the old unit out of my '88. Thanks very much for the excellent documentation.
-Jon
02-09-2005, 06:25 PM
#52
Drifting
Thread Starter
Sure Jon. What sort of tools/facilities do you have access to? As a minimum, you'll need access to a hydraulic press and some means of heating something as large as the aluminum transaxle case to 300 F or so. Another very desirable item would be a metal lathe to allow you to make some of the bushings needed to press in and out various bearing races, synchro hubs, etc. You can pretty much copy what you see in the factory shop manual (you absolutely will need the FSM section on transaxle rebuild) out of relatively cheap round aluminum barstock (as seen in some of my photos). If you don't have such access, a local machine shop might make some of these simple tools for not too much or you could try this link: http://www.emachineshop.com/download/index.htm A friend of mine uses this service and is very pleased with it. You will also need an in-lb range torque wrench similar to that seen in one of my photos. I got most of my bearing/seals/synchros from Pelican Parts.
03-20-2005, 04:03 PM
#53
I've rebuit a 928 5 spd transmission, but not a 944. Has anyone documented a rebuild on the web? I'm still waiting for my FSMs to show up and want to take my tranny apart to see if the problem is in the diff or the tranny itself. It clunks badly when its in gear and the shop said there was metal coming out with the gear oil when they drained it.
03-21-2005, 09:45 PM
#54
Drifting
Thread Starter
Pmooradian, are you asking about a web documented rebuild on a 928 or a 944 transaxle? I've only done the 944 and the documentation is in this thread. It seems that the weak link in the 944 unit is the ring & pinion. When mine went, it was a huge banging sound that made it undriveable. It lost about 1 and a half pinion gear teeth and the noise and vibration were more than clunks. I suspect most 944 R&P failures are not subtle enough to be called clunks. Maybe it's just a bad CV joint.
10-25-2006, 07:43 AM
#55
Since this is such a great thread.... What was the outcome? Did your efforts payoff?
Im going through the same process (minus RP replacement) and read through the whole thread.... But theres no ending!
Im going through the same process (minus RP replacement) and read through the whole thread.... But theres no ending!
10-25-2006, 07:58 AM
#56
Just a car guy
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This is a fairly common occurance with these gearboxes. I'm sure you guys have used the search function. If I can locate the old thread that Tifo started - I think there is some useful info there. If I do locate it - I'll post to it and bring it back to page one. Unfortunately, I did not photograph my rebuild - but I can probably offer some advice if needed. My guess is, Tifo can as well. 
10-26-2006, 08:04 PM
#58
Drifting
Thread Starter
My rebuild has been successful (so far). I have about 3,000 miles on the new R&P and all is quiet and smooth. It was a very satisfying project but I would not have taken it on without access to the (industrial) oven and metal lathe at work.
